Apparatus and method for embossing and printing elongated substrates

ABSTRACT

An apparatus and method for printing and embossing elongated substrates provide for both length and position registration with respect to the printed and embossed patterns. The ink pattern to embossed pattern error is corrected by stretching or relaxing the substrate between the printing and embossing assemblies.

The present application claims the benefit of U.S. ProvisionalApplication Ser. No. 60/073,086, filed Jan. 30, 1998, the disclosure ofwhich is hereby incorporated by reference herein.

FIELD OF THE INVENTION

The present invention relates in general to the art of embossing andprinting, and more particularly, to an apparatus and method for in-lineembossing and printing registered patterns onto elongated substratessuch as louvers and the like.

BACKGROUND OF THE INVENTION

Elongated louvers such as vertically and horizontally oriented slates ofthe type used in window treatment assemblies are well known in the artand commercially available in a wide variety of designs. The formationof louvers usually occurs through a forming machine, such as but notlimited to, an extruder which produces an elongated continuous louverfrom a hot melt thermoplastic material such as polyvinyl chloride (PVC)and the like.

The window treatment industry has recognized the desirability of forminga decorative pattern on at least one exposed surface of the louver. Byproviding various decorative patterns, various effects can be obtainedso as to provide a wide variety of products which will appeal to theconsumer, as well as satisfying various decorating goals. It has beenknown to form decorative patterns in a louver by embossing a desiredpattern or other like indication in at least one exposed surface of thelouver through the utilization of cooperative pairs of rollers engagingopposite surfaces of the louver. For example, Kierson, U.S. Pat. No.5,311,814 discloses an assembly for forming or embossing a decorativepattern on at least one exposed surface of an elongated slat preferablyof the type used in vertical blinds. The assembly includes a pair ofdriven rollers which are designed, dimensioned and configured to engageopposite sides of a slat immediately subsequent to its formation by aplastic extruder. The exterior surface of one of the rollers has adecorative pattern formed thereon, and when forced into confrontingengagement with an exposed surface of the slat, the decorative patternis transferred by an embossing technique. A similar embossing processfor laminated plastic panels is disclosed in Wellen, U.S. Pat. No.3,481,818.

In order to enhance the decorative appearance of the embossed louver, itis desirable to impart color to the louver. In particular, it has beendesired to provide color in a predetermined pattern, for example, withinthe valley formed during the embossing process. One approach isdisclosed in Lewicki, Jr., U.S. Pat. No. 3,887,678 by preprinting thesubstrate to be embossed with various colored ink in a predeterminedpattern using conventional rotogravure printing processes. This processhas rendered it extremely difficult, if not impossible, to providealignment of the pattern on the embossing roll with the printed patternon the substrate to be embossed. Hence, a mismatch between the twopatterns is often noted which detracts from the appearance of theresulting product.

Ruppel, et al., U.S. Pat. No. 5,339,730 discloses a method for printingand embossing sheets of paper made of cellulose wadding and with two ormore plies. The method discloses applying ink to one of the sheets as ittravels around a first embossing roller prior to being bonded with asecond sheet which passes around another embossing roller. The resultingprinted pattern is sandwiched between the two sheets which are gluedtogether.

Terwilliger, U.S. Pat. No. 4,112,189 discloses a process for multicolorvalley printing and embossing of flooring material. The apparatusincludes a rotatable embossing and printing roll having an engravedsurface contour representing a decorative pattern to be embossed andprinted on a sheet of flooring material. A plurality of rotatablepattern rolls are arranged in operative engagement with the surface ofthe embossing and printing roll. Each pattern roll is designed toreceive a different color ink and to transfer the ink to a discretesurface area of the embossing and printing roll in a manner such thatcertain portions of the surface area thereof receive one color ink froma single pattern roll and other portions thereof receive overlappinglayers of different color inks from at least two pattern rolls. Thepattern rolls are formed with raised portions corresponding topredetermined discrete raised surface areas of the embossing andprinting roll to which ink from such pattern roll is to be applied. Fromthe foregoing, it can be appreciated that there is the requirement formaintaining proper alignment between the pattern rolls and the engravedsurface of the printing and embossing roll. To accomplish thisregistration, the embossing and printing roll, the pattern rolls, aswell as the inking rolls of the ink transfer system must all beoperatively linked together by a gear train which is driven by a motor.

Snyder, U.S. Pat. No. 3,850,095 discloses an apparatus and method forembossing and valley printing of carpets with a hot melt ink. In thedisclosed apparatus, hot melt ink is transferred from a pickup rollimmersed in the liquefied hot melt ink to a transfer roll. From thetransfer roll, the hot melt ink is transferred to a inking roll which isin operative engagement with a printing and embossing roll.

Portnoy, et al., U.S. Pat. No. 3,681,159 discloses an apparatus andmethod for producing a textured printed surface on rigid laminatedboards by printing and embossing. Registration of the printed patternand the embossed pattern is achieved by providing the printing andembossing rolls of identical diameter and driving them at identicalrotational speeds from a single power source. Based upon thisconstruction, there is no flexibility to accommodate any variations inthe construction of the individual components of the apparatus orlaminated boards which during operation of the printing and embossingoperation may affect registration.

Other techniques known to effect registration between an ink pattern andan embossed pattern include the use of compensator rolls and phasechange rolls. In the case of compensator rolls, a movable compensatorroll is positioned between the printing and embossing assemblies overwhich the substrate to be printed and embossed passes. The compensatorroll is displaced transverse to the straight line path of travel betweenthe printing and embossing assemblies. This effectively lengthens orshortens the path of travel of the substrate between the printing andembossing assemblies to effect registration of the patterns. Phasechange rolls, on the other hand, change the surface speed of theprinting or embossing roll so as to be greater or less than theadvancing speed of the substrate to be printed or embossed. Althoughthis allows for effective registration, it suffers from the disadvantageof causing smudging of the printed ink or variations in the embossedpattern due to the differences between the surface speed of the printingor embossing roll and the surface speed of the substrate.

Accordingly, there is an unsolved need for further improvements in anapparatus and method for embossing and printing elongated substrateswith registered patterns.

SUMMARY OF THE INVENTION

An object of the present invention is to provide an apparatus and methodfor embossing and printing elongated substrates of polymer materialhaving elastic properties with a first and second pattern which arebrought into registration with each other.

Another object of the present invention is to provide an apparatus andmethod for embossing and printing elongated substrates whereinregistration between the printed and embossed patterns is achieved bystretching or relaxing the length of the substrate between the printingand embossing assemblies.

Another object of the present invention is to provide an apparatus andmethod for embossing and printing elongated substrates wherein the inkpattern printed on the substrate is length registered with the embossingpattern to be embossed on the substrate.

Another object of the present invention is to provide an apparatus andmethod for embossing and printing elongated substrates wherein the inkpattern on the substrate is position registered with the embossingpattern to be embossed on the substrate.

In accordance with one embodiment of the present invention there isdescribed a method for applying a second repeating pattern onto thesurface of a substrate in registration with a first repeating pattern onthe substrate, the method comprising advancing a substrate past themoving surface of a first application member having a first pattern inoperative association therewith; repeatedly applying the first patternto one side of the substrate as it is advanced past the firstapplication member; advancing the substrate past the moving surface of asecond application member having a second pattern in operativeassociation therewith, the first pattern having a repeat lengthdifferent than a repeat length of the second pattern; controlling themoving surfaces of the first and second application members at speedsrelative to one another so that the length of the substrate is alteredwhereby the repeat length of the applied first pattern on the substratecorresponds to the repeat length of the second pattern; and repeatedlyapplying the second pattern to the one side of the substrate inregistration with the altered first pattern as it is advanced past thesecond application member.

In accordance with another embodiment of the present invention there isdescribed a method for applying a second repeating pattern onto thesurface of a substrate in registration with a first repeating pattern onthe substrate, the method comprising advancing a substrate through a nipformed between opposing moving surfaces of a printing roll and a backingroll; supplying a continuous film having an ink pattern on one sidethereof through the nip with the ink pattern facing one side of thesubstrate; repeatedly applying the ink pattern to the one side of thesubstrate as the substrate and the film are advanced through the nip;advancing the substrate past the moving surface of an embossing rollhaving an embossing pattern thereon, the ink pattern having a repeatlength smaller than a repeat length of the embossing pattern; repeatedlyapplying the embossing pattern to the one side of the substrate inregistration with the ink pattern as the substrate is advanced past theembossing roll; and controlling the speed of the embossing roll relativeto the printing roll so that the length of the substrate is stretched orrelaxed whereby the repeat length of the applied ink pattern on thesubstrate substantially corresponds to the repeat length of theembossing pattern and the applied ink pattern is maintained in positionregistration with the embossing pattern.

In accordance with another embodiment of the present invention there isdescribed a method for applying a second repeating pattern onto thesurface of a substrate in a plastic condition in registration with afirst repeating pattern on the substrate, the method comprising passingthe substrate past the moving surface of a first treating member havinga first treating element in relation to a pattern receiving side of thesubstrate, the first treating element having a first pattern that isrepeatedly applied to the pattern receiving side of the substrate as itpasses; passing the substrate past the moving surface of a secondtreating member having a second treating element in relation to thepattern receiving side of the substrate, the second treating elementhaving a second pattern that is repeatedly applied to the patternreceiving side of the substrate as it passes; initially operating themoving surfaces of the first and second treating members at speedsrelative to one another so that the substrate is stretched or relaxed tobring the first and second patterns into registration; and operating themoving surfaces of the first and second treating members at speeds afterthe registration of the first and second patterns so that theregistration of the patterns is maintained.

BRIEF DESCRIPTION OF THE DRAWINGS

The above description, as well as further objects, features andadvantages of the present invention will be more fully understood withreference to the following detailed description of a method andapparatus for embossing and printing elongated substrates, when taken inconjunction with the accompanying drawing wherein:

FIG. 1 is a diagrammatic illustration of the apparatus and method forembossing and printing elongated substrates in accordance with oneembodiment of the present invention.

FIG. 2 is a top plan view taken along lines 2—2 in FIG. 1.

FIG. 3 is a diagrammatic illustration of a master controller for use inaccordance with one embodiment of the present invention.

FIG. 4 is a diagrammatic illustration of an encoder for determining thesurface speed of the ink transfer roll or embossing roll.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In describing the preferred embodiments of the subject matterillustrated and to be described with respect to the drawings, specificterminology will be resorted to for the sake of clarity. However, theinvention is not intended to be limited to the specific terms soselected, and is to be understood that each specific term includes alltechnical equivalence which operate in a similar manner to accomplish asimilar purpose.

Referring now to the drawings, where like reference symbols representlike elements, there is shown in FIG. 1 an apparatus for embossing andprinting elongated substrates which is generally designated by reference100. As previously noted, the present invention is intended to have itsprimary application for embossing and printing of elongated substratessuch as louvers in the nature of slats utilized for decorative windowtreatments, for example, vertical and horizontal blinds. However, it isto be understood that the present invention may be applied to theembossing and printing of other substrates which may be embossed andprinted, for example, continuous lengths of synthetic elastic materialsfor use as decorative coverings such as polymer wall coverings,furniture, housesiding and the like. In addition, although the louvershave been described as being constructed from PVC material, it is to beunderstood that any other similar elastic materials such as polymerswhich can be embossed and printed are suitable for use with theapparatus and method of the present invention. The apparatus and methodof the present invention will now be described with respect to embossingand printing of elongated louvers formed of PVC material by way ofillustration only.

The apparatus 100 of the present invention includes a printing assembly102 generally defined within the dashed lines 104 and an embossingassembly 106 generally defined within the dashed lines 108. Broadly, theprinting assembly 102 is operative for printing an ink pattern onto onesurface of a substrate 110 such as a louver which is being advancedthrough the apparatus 100. After being printed, the substrate 100 isadvanced, in line, to the embossing assembly 106 where the substrate isembossed in predetermined registration with the ink pattern to producethe resulting product having the decorator appearance desired, i.e., anink pattern and an embossed pattern.

One aspect of the apparatus 100 for printing and embossing the substrate110 is the ability to register the ink pattern in length registrationwith the embossed pattern, as well as providing position registrationbetween the ink pattern and embossed pattern. By length registration itis meant that the repeat length of the ink pattern when advanced throughthe embossing assembly 106 corresponds to the repeat length of theembossed pattern. As such, there is a one to one correspondence inlength between the ink pattern and the embossed pattern to provideperfect length registration therebetween. On the other hand, positionregistration refers to maintaining the position of the ink pattern onthe substrate 110 in proper positional relationship or registration withthe embossed pattern on the substrate. By virtue of the apparatus 100providing both length registration and position registration, theapparatus is operative for printing and embossing substrates 110 havingelastic properties with overall registration of the two patterns.

The printing assembly 102 includes a rotationally journaled ink transferroll 112 and backup roll 114 arranged opposing one another so as todefine a nip 116 therebetween. Ink transfer roll 112 is preferablycoated with a rubber coating such as Hyalon rubber, which is a manmadecoating having about an 80 durometer, with a thickness of the coating ofabout three quarters of an inch. The ink transfer roll 112 can beobtained from American Roll of Union Grove, Wis. On the other hand, thebackup roll 114 is generally not provided with a rubber coating. Forexample, backup roll 114 may be in the nature of a steel roll with atitanium outer coating.

The ink transfer roll 112 is driven by a variable speed AC lead motordrive 118 by means of a suitable linking assembly 120 such as a drivechain or drive belt. Operation of the motor drive 118 is controlled by asuitable controller 122, both of which are well known in the art. Thelinking assembly 120 is operatively engaged with a driven sprocket 124or pulley which is attached to one end of the ink transfer roll 112 orshaft (not shown) about which the roll is journaled.

The printing assembly 102 further includes an ink transfer paper supplyroll 126 and a release paper rewind roll 128. The supply roll 126 andrewind roll 126 are operative for continuously advancing a preprintedink transfer tape 130 through the nip 116 formed between ink transferroll 112 and backup roll 114. The ink transfer tape 130 is a compositetape as shown in FIG. 2 which includes a color preprinted ink pattern132 deposited on one surface of a release paper 134. The ink pattern 132may be coated with an adhesive layer (not shown) which will adhere tothe substrate 110 during the printing process. Alternatively, theadhesive can be formulated within the ink pattern 132 itself. Transfertapes 130 of the foregoing construction are available from EnhancedTechnologies Corporation of Murray Hill, N.J. These transfer tapes 130can be obtained in various predetermined colors and patterns as may bedesired.

The printing assembly 102 is supported by a support structure (notshown) which allows for lateral displacement with respect to theembossing assembly 106 as to be described hereinafter. Positionedbetween the printing assembly 102 and embossing assembly 106 is a heater135 which is operative for post-heating the substrate 110 received fromthe printing assembly 102 so as to maintain proper temperature of thesubstrate for embossing. Heaters 135 suitable for maintaining the propertemperature of the substrate 110 are well known in the art.

The embossing assembly 106 includes an embossing roll 136 and a backuproll 138. The embossing roll 136 is a standard embossing roll of metalconstruction which is well known for use in the art of embossing. Thesurface 140 of the embossing roll 136 is patterned with a predeterminedpattern of raised portions 141. The embossing pattern to be formed inthe surface 140 of the embossing roll 136 may be formed using a varietyof manufacturing techniques, such as by chemical etching, milling orrouting such as disclosed in Morrison, et al., U.S. Pat. No. 5,771,796.

The backup roll 138 is rotatably journaled opposing the embossing roll136 to define a nip 142 therebetween. The surface 144 of the backup roll138 is preferably coated with a rubber coating such as Hyalon rubber, aspreviously noted with respect to the ink transfer roll 112. As thematerial to be embossed is generally in the nature of a hot extruded PVCmaterial, the embossing roll 136 and backup roll 138 are generally watercooled by supplying water thereto through supply pipes 146, 148,respectively.

The embossing roll 136 is coupled to a driven sprocket 150 or pulley atone end thereof or to a shaft (not shown) for rotation by a variablespeed AC follower drive motor 152 having a suitable controller 154. Thedrive motor 152 is operatively coupled to the sprocket 150 by means of alinking assembly 156 such as a drive chain or drive belt. In general,the lead and follower drive motors 118, 152 and controllers 122, 154 maybe of the same design and construction. In this regard, both of thedrive motors 118, 152 are operative for receiving speed control signalsfrom the controllers 122, 154.

The apparatus 100 is provided with a computerized control system whichgenerally includes encoders 158, 160, photoelectric eye 162 or othersimilar device and a master controller 164 as shown in FIG. 3. Themaster controller 164 is operative for receiving input signals from theencoders 158, 160 and photoelectric eye 162 and outputting theappropriate control signals for controlling the motor drives 118, 152.Output control signals are sent from the master controller 164 primarilyto the controller 154 for the follower drive motor 152. However, themaster controller 164 can also send output signals to the controller 122of the lead drive motor 118 if so desired. One master controller 164suitable for use with the apparatus 100 of the present invention isknown as M-Rotary Controller, a digital motion controller, availablefrom Powermation, Inc. of St. Paul, Minn.

The encoders 158, 160, as partially shown diagrammatically in FIG. 4,include a wheel 166 coupled to the shaft 168 of the ink transfer roll112 and embossing roll 136. The wheel 166 is provided with 1,200openings 170 arranged about the circumference of the wheel. A laser 172or other light source is operative for transmitting light through theopenings 170 as the wheel 166 is rotated. An electronic eye 174 or othersimilar device counts the blips corresponding to each time light fromthe laser 172 passes through an opening 170. By counting the number ofblips, the encoders 158, 160 can determine the surface speed for the inktransfer roll 112 and embossing roll 136 of a given diameter. Inaddition, the encoder 160 is operative for determining each time theembossing pattern on the embossing roll 136 makes one completerevolution.

Referring once again to FIG. 2, the transfer tape 130 is provided withan ink pattern 132 having a predetermined pattern length as definedbetween the vertical marks 176, 178. This repeat pattern is repeatedlyprinted on the surface of the substrate 110 by means of the printingassembly 102. Subsequently, the embossing assembly 106 will emboss thesurface of the substrate 110 overlying the ink pattern 132. In order toprovide the resulting printed and embossed substrate 110 with thedesired pattern registration, it is desired that the ink pattern 132 bemaintained in length registration with the embossed pattern, as well asbeing maintained in position registration therewith. Thus, by providingboth length registration and position registration between the inkedpattern 132 and embossed pattern, the resulting printed and embossedsubstrate 110 will have an enhanced visual appearance.

The apparatus 100 having now been described, the method of the presentinvention for printing and embossing elongated substrates havingregistered patterns will now be described. The following descriptionwhich will refer to specific dimensions is to be understood as merely anillustrative example. As previously noted, one function of the apparatus100 is to provide length registration between the ink pattern 132 on thetransfer tape 130 with the embossed pattern on the surface 140 of theembossing roll 136. In this regard, the length of the embossing patternon the surface 140 of the embossing roll 136 is designed to be slightlygreater than the repeat length of the inked pattern 132 on the transfertape 130. This is achieved by designing the circumference of theembossing roll 136 to be slightly greater than the repeat length of theink pattern 132. By way of example, the circumference of the embossingroll 136 is 17.988 inches, while the repeat length of the inked pattern132 is 17.970 inches. In other words, the embossing pattern on theembossing roll 136 is greater than the repeat length of the ink pattern132 by 0.018 inches.

In order for the repeat length of the ink pattern 132 to match therepeat length of the embossing pattern on the embossing roll 136, therepeat length of the ink pattern needs to be increased by 0.018 inches.This is achieved by stretching the substrate 110 in the region betweenthe spaced apart nips 116, 142 which are formed respectively between theink transfer roll 112 and backup roll 114 and embossing roll 136 andbackup roll 138. The substrate 110 may be stretched by controlling thesurface speed of the embossing roll 136 to be slightly greater than thesurface speed of the ink transfer roll 112. During operation of theapparatus 100, the degree of stretching can be controlled by monitoringand controlling the difference between the surface speeds between theembossing roll 136 and ink transfer roll 112.

During normal operation of the apparatus 100, the degree of stretchingof the substrate 110 can be increased or decreased (such as by relaxingthe substrate) to accommodate process variations whereby the repeatlength of the ink pattern 132 will be maintained identical to the repeatlength of the embossing pattern on the embossing roll 136. If the repeatlength of the ink pattern 132 increases greater than the circumferenceof the embossing roll 136, the substrate 110 may be relaxed to decreaseits repeat length. Alternatively, should the repeat length of the inkpattern 132 decrease, it may be increased by increasing the surfacespeed of the embossing roll 136. The foregoing operation can becontrolled by means of the master controller 164 which is operative foroutputting speed control signals to the controller 154 of the followerdrive motor 152.

It is also desired that the ink and embossed patterns be aligned inposition registration with each other. Depending upon the desiredthroughput of the apparatus 100, the rolls 112, 114 are driven at apredetermined set speed by means of the lead drive motor 118 andcontroller 122 under operation of the master controller 164. Onethroughput speed for the apparatus 100 for embossing and printing asubstrate 100 such as a louver is about 30-50 feet per minute of linearsubstrate speed. At initial startup, it is desired that the surfacespeed within the nips 116, 142 be substantially or very close to eachother, regardless of where the registration is between the ink pattern132 and embossing pattern on the embossing roll 136.

During operation of the apparatus 100, the encoders 158, 160 determinethe surface speed of the ink transfer roll 112 and embossing roll 136 bymeans of the number of blips obtained from signals received by theelectric eyes 174. In this regard, although there are 1,200 openings 170within the wheel 166, the encoders 158, 160 are operative fordetermining a signal both at the beginning and tailing end of theopenings 170 to provide 2,400 blips, thereby increasing the accuracy ofthe surface speed determination. Encoder 158 outputs a signalcorresponding to the surface speed of ink transfer roll 112 to themaster controller 164. Similarly, encoder 160 outputs a signalcorresponding to the surface speed of the embossing roll 136 to themaster controller 164.

The encoder 160 is also operative for determining each time thebeginning of the repeat length of the embossing pattern on the embossingroll 136 makes one complete revolution, which signal is input to themaster controller 164. The master controller 164 is now receivinginformation concerning the surface speed of ink transfer roll 112, thesurface speed of embossing roll 136, and a signal corresponding to eachtime the embossing pattern on the embossing roll makes one completerevolution. This is diagrammatically illustrated in FIG. 3 with themaster controller 164 receiving one signal from encoder 158 and twosignals from encoder 160.

The photoelectric eye 162 is positioned for detecting tick marks 180,see FIG. 2, which are imprinted on the back side of the transfer tape130. The tick marks 180 are aligned with the beginning and end of theinked pattern 132. As shown in FIG. 1, the distance the transfer tape130 travels between the location of the nip 116 and the location of thephotoelectric eye 162 is the same distance the substrate 110 travelsbetween the nip 116 and a predetermined location 182. This distancebetween the nip 16 and location 182 can be adjusted as previouslydescribed by moving the printing assembly 102 laterally such as by usinga lead screw (not shown) provided on the support structure for theprinting assembly 102. In addition to the foregoing spaced arrangement,the distance between predetermined location 182 and the nip 142 definedbetween the embossing roll 136 and backup roll 138 is a whole multipleof the repeat pattern length of the embossing pattern on the embossingroll 136. In other words, the distance between location 182 and nip 142corresponds to a whole multiple of the circumference of the surface 140of the embossing roll 136.

In order to obtain position registration between the ink pattern 132 andembossed pattern, it is required that the signal generated from encoder160 as to the completion of one revolution of the embossing roll 136,which indicates the beginning location of the embossing pattern,coincide with receipt of the signal received from the photoelectric eye162 as to the detection of the beginning of the ink pattern 132. Themaster controlled 164 will control the rotational speed of the embossingroll 136 in order to have the signals from the photoelectric eye 162 andrevolution signals from the encoder 160 be receiving simultaneously. Inthis manner, the embossing assembly 106 is the follower apparatus whichis controlled or allowed to follow the printing assembly 102 which isthe lead apparatus. Since the circumference of the embossing roll 136 isgreater than the repeat length of the ink pattern 132 by 0.018 inches,the master controller 164 will increase the rotational speed of theembossing roll. Hence, the substrate 110 will also be stretched as thesurface speed of the embossing roll 136 will be greater than the surfacespeed of the ink transfer roll 112. The resulting operation will notonly stretch the substrate 110 so as to achieve the desired lengthregistration, but will also provide the desired position registration.

The rotational speed of the embossing roll 136 can be increased underthe programmed operation of the master controller 164. In this regard,as previously noted, the encoder 160 counts the number of blipsresulting from the openings 170 in wheel 166. By operation of the mastercontroller 164, a predetermined number of blips may be added orsubtracted from the actual number counted so as to change the rotationalspeed of the embossing roll 136. For example, adding blips to the countwill decrease the rotational speed of the embossing roll 136, whilesubtracting blips from the count will increase the rotational speed ofthe embossing roll.

From the foregoing description, if the ink pattern registration signalfrom the photoelectric eye 162 does not take place at the same time asthe embossing pattern registration signal from the encoder 160, a plusor minus speed change will be made to the embossing roll 136 byoperation of the master controller 164. The speed change of theembossing roll 136 will continue so as to stretch or relax the printedsubstrate 110, as may be required, until such time as the pulses fromthe photoelectric eye 162 and encoder 160 are simultaneously received.Because the location of the photoeye 162 corresponds to location 182,and because the distance between location 182 and nip 142 is a wholemultiple of the embossing pattern length, the printed ink pattern on thesubstrate within the embossing assembly 106 will be in both length andposition registration with the embossing pattern on the embossing roll136. During continued operation of the apparatus 100, the substrate 110may be stretched or relaxed as may be required to maintain properregistration, both in length and position, with respect to the inkpattern and embossed pattern.

The substrate 110 such as a louver is formed from hot extruded PVCmaterial from extruder 184 having an initial temperature of about450-500° F. which is fed to the nip 116 between rolls 112, 114. At thenip 116, one surface of the substrate 110 is printed with the inkpattern 132 from the transfer tape 130 which is continuously beingadvanced therethrough by means of the rewind roll 128. As the inkpattern 132 is printed onto the substrate 110, the release paper 134 isstripped therefrom and wound upon the rewind roll 128. Subsequently, theprinted substrate 110 is heated by means of heater 135 to maintainproper embossing temperature. Subsequent to embossing by the embossingroll 136, the substrate is cooled by virtue of the embossing roll andbackup roll 138 being water cooled. The output temperature of thesubstrate 110 is generally in the range of about 250-300° F. The coolingof the substrate 110 is generally preferred so as to set the embossing.

The process of the present invention provides embossing a decorativepattern onto the surface of an ink printed elastic substrate, e.g.,extruded PVC louver material, in perfect registration with the inkprinted repeat pattern. The embossed pattern to ink pattern registrationerror is corrected by stretching or relaxing the elastic substrate andnot by the use of conventional methods such as compensator rolls, phasechange rolls, etc. as used on non-elastic webs such as paper and foils.

Although the invention herein has been described with reference toparticular embodiments, it needs to be understood that these embodimentsare merely illustrative of the principles and applications of thepresent invention. It is therefore to be understood that numerousmodifications may be made to the illustrative embodiments and that otherarrangements have been devised without departing from the spirit andscope of the present invention as defined by the appended claims.

What is claimed:
 1. A method for applying a second repeating patternonto the surface of a substrate in registration with a first repeatingpattern on said substrate, said method comprising advancing a substratepast the moving surface of a first application member having a firstpattern in operative association therewith; repeatedly applying saidfirst pattern to one side of said substrate as it is advanced past saidfirst application member; advancing said substrate past the movingsurface of a second application member having a second pattern inoperative association therewith, said first pattern having a repeatlength different than a repeat length of said second pattern;controlling said moving surfaces of said first and second applicationmembers at speeds relative to one another so that the length of saidsubstrate is altered whereby the repeat length of the applied firstpattern on said substrate corresponds to the repeat length of saidsecond pattern; and repeatedly applying said second pattern to said oneside of said substrate in registration with the altered first pattern asit is advanced past said second application member.
 2. The method ofclaim 1, wherein said first application member is a first roll having arotating surface in printing relation to said one side of said substrateand said second application member is an embossing roll having arotating surface in embossing relation to said one side of saidsubstrate.
 3. The method of claim 1, further comprising controlling thesurface speed of said second application member greater than the surfacespeed of said first application member so that length registration ofsaid first and second patterns is maintained.
 4. The method of claim 3,further comprising controlling the surface speed of said embossing rollrelative to the surface speed of said first roll to bring said first andsecond patterns into position registration.
 5. The method of claim 4,further comprising advancing a film supporting said first pattern intooperative association with said first application member.
 6. The methodof claim 5, further comprising providing a first signal indicative ofeach time the beginning of said first pattern on said film passes apredetermined location and providing a second signal indicative of eachtime the beginning of said second pattern passes a predeterminedlocation, and controlling the speed of said second application member tosynchronize said first and second signals.
 7. The method of claim 1,wherein said first pattern has a repeat length less than the repeatlength of said second pattern.
 8. The method of claim 7, wherein saidsubstrate is stretched by controlling the surface speed of said secondapplication member greater than the surface speed of said firstapplication member.
 9. The method of claim 1, wherein the length of saidsubstrate is altered by stretching or relaxing said substrate duringsaid controlling of said moving surfaces of said first and secondapplication members.
 10. The method of claim 1, wherein thecircumference of said second application member is greater than therepeat length of said first pattern.
 11. The method of claim 1, whereinsaid substrate comprises a louver.
 12. The method of claim 1, whereinsaid substrate is formed of a material having elastic properties.
 13. Amethod for applying a repeating embossing pattern onto the surface of asubstrate in registration with a repeating ink pattern on saidsubstrate, said method comprising advancing a substrate through a nipformed between opposing moving surfaces of a printing roll and a backingroll; supplying a continuous film having an ink pattern on one sidethereof through said nip with said ink pattern facing one side of saidsubstrate; repeatedly applying said ink pattern to said one side of saidsubstrate as said substrate and said film are advanced through said nip;advancing said substrate past the moving surface of an embossing rollhaving an embossing pattern thereon, said ink pattern having a repeatlength smaller than a repeat length of said embossing pattern;repeatedly applying said embossing pattern to said one side of saidsubstrate in registration with said ink pattern as said substrate isadvanced past said embossing roll; and controlling the speed of saidembossing roll relative to said printing roll so that the length of saidsubstrate is stretched or relaxed whereby the repeat length of theapplied ink pattern on said substrate substantially corresponds to therepeat length of said embossing pattern and the applied ink pattern ismaintained in position registration with said embossing pattern.
 14. Themethod of claim 13, further comprising controlling the surface speed ofsaid embossing roll greater than the surface speed of said printing rollso that length registration of said ink and embossing patterns ismaintained.
 15. The method of claim 14, further comprising controllingthe surface speed of said embossing roll relative to the surface speedof said printing roll to bring said first and second patterns into saidposition registration.
 16. The method of claim 13, further comprisingproviding a first signal indicative of each time the beginning of saidink pattern on said film passes a predetermined location and providing asecond signal indicative of each time the beginning of said embossingpattern passes a predetermined location, and controlling the speed ofsaid embossing roll to synchronize said first and second signals. 17.The method of claim 13, wherein said ink pattern has a repeat lengthless than the repeat length of said embossing pattern.
 18. The method ofclaim 13, wherein said substrate is stretched or relaxed by controllingthe surface speed of said embossing roll greater or less than thesurface speed of said printing roll.
 19. The method of claim 13, whereinsaid substrate comprises a louver of polymer material.
 20. A method forapplying a second repeating pattern onto the surface of a substrate in aplastic condition in registration with a first repeating pattern on saidsubstrate, said method comprising passing said substrate past the movingsurface of a first treating member having a first treating element inrelation to a pattern receiving side of said substrate, said firsttreating element having a first pattern that is repeatedly applied tosaid pattern receiving side of said substrate as it passes; passing saidsubstrate past the moving surface of a second treating member having asecond treating element in relation to said pattern receiving side ofsaid substrate, said second treating element having a second patternthat is repeatedly applied to said pattern receiving side of saidsubstrate as it passes; initially operating said moving surfaces of saidfirst and second treating members at speeds relative to one another sothat said substrate is stretched or relaxed to bring said first andsecond patterns into registration; and operating said moving surfaces ofsaid first and second treating members at speeds after the registrationof said first and second patterns so that the registration of saidpatterns is maintained.
 21. The method of claim 20, wherein said firsttreating member is a first roll having a rotating surface in printingrelation to said pattern-receiving side of said substrate; said secondtreating member is an embossing roll having a rotating surface inembossing relation to said pattern-receiving side of said substrate; andthe surface speed of said embossing roll is initially operated relativeto the surface speed of said first roll to bring said first and secondpatterns into registration.